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Old 07-09-2014, 10:58 AM   #1
Motion Machine
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Default What's wrong with this picture?

Here's another failed 2.5 that was brought to me to try and straighten out. Freshly sleeved and line honed, it scored 2 pistons and spun a rod bearing. I knew what the piston problem was without even measuring the bores, gaging them showed the same problem I've seen many times, .002"-.0025" tight in the bottom, .001" loose in the middle. This is a result of a hone incapable of sizing the bore the entire length of the cylinder. The line hone job (no case half machining, just bolt and hone) was hideous and #4 and #5 were still almost .002" out of round. Can anyone spot part of the problem?
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Old 07-09-2014, 11:04 AM   #2
BeastianSTI
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Quote:
Originally Posted by Motion Machine View Post
Here's another failed 2.5 that was brought to me to try and straighten out. Freshly sleeved and line honed, it scored 2 pistons and spun a rod bearing. I knew what the piston problem was without even measuring the bores, gaging them showed the same problem I've seen many times, .002"-.0025" tight in the bottom, .001" loose in the middle. This is a result of a hone incapable of sizing the bore the entire length of the cylinder. The line hone job (no case half machining, just bolt and hone) was hideous and #4 and #5 were still almost .002" out of round. Can anyone spot part of the problem?
Dang that is some serious scuffing on the cylinder walls
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Old 07-09-2014, 11:16 AM   #3
ALOKIN
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Can anyone spot part of the problem?
Its an EJ
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Old 07-09-2014, 12:06 PM   #4
Racebug1098
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pry marks on the case not letting it pull up tight
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Old 07-09-2014, 12:35 PM   #5
2000subie
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Looks like both alignment dowels are pressed in crooked.
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Old 07-09-2014, 12:44 PM   #6
Motion Machine
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pry marks on the case not letting it pull up tight
Good guess but they actually did file off the high spots
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Old 07-09-2014, 12:44 PM   #7
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Looks like both alignment dowels are pressed in crooked.
Getting closer.....
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Old 07-09-2014, 12:58 PM   #8
beef
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Default Welding?

Looks like one of the dowels was welded in..
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Old 07-09-2014, 01:25 PM   #9
FuJi K
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That dowel in the upper back though....
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Old 07-09-2014, 02:25 PM   #10
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That dowel in the upper back though....
We have a winner. Except you don't actually win anything.
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Old 07-09-2014, 02:32 PM   #11
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That dowel in the upper back though....
The one on the left of the pic (rear of engine) sticking up too high? Or, is there one missing?
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Old 07-09-2014, 02:36 PM   #12
evilfirbolg
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The one on the left of the pic (rear of engine) sticking up too high? Or, is there one missing?

Um...sorta. I don't think it's supposed to be there. And the one that is suposed to in the "upper back" ain't there.
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Old 07-09-2014, 02:38 PM   #13
FuJi K
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Ugh! If it was someone else, probably. ...

I need R180 axle seals; left/right. Please?!



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We have a winner. Except you don't actually win anything.
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Old 07-09-2014, 02:48 PM   #14
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The one on the left of the pic (rear of engine) sticking up too high? Or, is there one missing?
Yes, it is sticking up too high because it's in the wrong hole. The total depth to the steps in these two "wrong" holes is .980". The dowel is 1.025". The only reason it worked was because the dowels are tapered on both ends, just enough to clear the step in the holes.
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Old 07-09-2014, 04:01 PM   #15
uglybetty
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This kind of attention to detail makes me even happier that I sent you my block to machine. You're the best Dale.
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Old 07-09-2014, 09:36 PM   #16
sidewayz
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Who the eff puts the dowls in the wrong spots?
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Old 07-10-2014, 12:28 AM   #17
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Old 07-10-2014, 08:04 AM   #18
Motion Machine
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Who the eff puts the dowls in the wrong spots?
I don't know who did the machine work, don't wanna know. I don't even know what shop is building the motor, this came to me from another machine shop who knew better than to mess with a Suby. And this is a machinist who's ability I hold in high regard. Obviously whatever shop it was doesn't know Suby's very well if they got that little detail wrong. I wish I could say that this quality of work is unusual but unfortunately it's not. And another problem is rearing it's ugly head on this block. You can see in the 2nd picture that there was a lot of "trauma" around the front dowel hole, somebody beat the crap out of the block trying to get it apart. The hole was slightly damaged on the leading edge but the dowel went in properly after de-burring. After I milled the mating surfaces in preparation for line boring, I torqued the halves together and they are not aligning well in the front, acting as if the front dowel was bent. It's not, I always qualify them before I re-install. Checking with a 90 degree fixture I can clearly see that the dowel is not square to the block, it tips in the same direction as the misalignment. Removed dowel, reinstalled 180 degrees, same problem. So the actual hole in the case is now whack. To make matters worse, the last shop tried to line hone the misalignment out of it, instead of correcting the dowel problem. Sometimes I bitch too much about shops doing poor quality work but this is why. It makes my job harder and it takes all the profit out of it. And another thing, someone also did the unthinkable to this block, they took a scotchbrite pad/ziz wheel/cookie duster to the mating surfaces. I took .003" off each case and there are spots where it didn't clean up thanks to that weapon of mass destruction.
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Old 07-10-2014, 08:59 AM   #19
sidewayz
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I hate when people use cookies or bristle discs to the surface. Even tho fsm says a white bristle disc is ok. Eff that.
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